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If you have had the car for 8 years and 110k miles and kept up on maintenance, you pretty much knows what has been replaced and what needs to be replaced in the future. Right now, assuming you can do...

If one simply looks at the 25mph test alone, the only failing parameter is elevated HC. Everything else is actually quite good for a 22 year old car. No O2, average CO and slightly high NO but still...

I have an E36 M3 flywheel/clutch/pp combo in my 530 and it is most definitely a heavier pedal feel and shorter engagement. I did get the flywheel for free, so that throws off the $-equation somewhat....

If you use the 528 long block and your intake manifold with throttle body, I don't see any reason why the existing 525 ECU would not be able to compensate for a 12% increase in cylinder displacement....